Methods for applying a bioactive coating onto a surface of an implant

ABSTRACT

Devices, systems, and methods for applying a bioactive coating to an exterior surface of an implant are disclosed. In some embodiments, the bioactive coating may be applied to the surfaces of the implant within the operating room at the time of implantation. In one embodiment, the implant may be a temporary spacer used to temporary replace an implant in a patient suffering from an infection. The temporary spacer being, for example, an antibacterial material for fighting the infection. In some embodiments, the method includes providing a mold of the implant, and providing the bioactive coating within the mold. The method may further include inserting the implant into the mold so that the exterior surface of the implant contacts the bioactive coating, and then removing the implant from the mold.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of pending U.S. application Ser. No.16/291,914, filed Mar. 4, 2019, entitled “Methods for Applying aBioactive Coating onto a Surface of an Implant,” which claims priorityto, and the benefit of, U.S. provisional patent application No.62/638,701, filed Mar. 5, 2018, entitled “Devices and Methods forApplying a Bioactive Coating Onto a Surface of an Implant” and claimspriority to, and the benefit of, U.S. provisional patent application No.62/638,991, filed Mar. 6, 2018, entitled “Devices and Methods forApplying a Bioactive Coating Onto a Surface of an Implant,” the entirecontents of which applications are incorporated by reference herein.

TECHNICAL FIELD

The present disclosure generally relates to medical devices, and moreparticularly, but not exclusively, relates to methods, systems, anddevices for applying a bioactive coating onto surfaces of an implant.For example, in one embodiment, the present disclosure relates tomethods, systems, and devices for applying a bioactive coating ontosurfaces of a temporary spacer, the bioactive coating being applied tothe spacer within a surgical environment such as, for example, anoperating room.

BACKGROUND

It is commonly known to coat medical implants with one or more bioactivecoatings. For example, it is known to coat the surfaces of an implantwith a bioactive coating such as, for example, an antimicrobial coating,an antibacterial coating, a hydrogel, a paste, etc. The bioactivecoating containing one or more biological compounds such as, forexample, antimicrobials, antibiotics, growth factors. etc.

However, one problem with coated implants is that the lifespan of thecoating may be shorter than the lifespan of the medical implant. Thus,it would be advantageous to provide a device, system, and/or method forapplying a coating to the implant when needed, for example, in theoperating room.

One known approach for applying a coating to the implant in, forexample, the operating room is to use a syringe with a small spreaderattached to the nozzle of the syringe to allow medical personnel toslowly dispense the coating over the required surfaces of the implant.

For a number of reasons, it would be beneficial to utilize a device,system, and method for applying a coating to the implant in, forexample, the operating room that is faster and more accurate. As such, aneed remains for further improvements in this technological field. Thepresent disclosure addresses this need.

SUMMARY

The Summary is provided to introduce a selection of concepts in asimplified form, the concepts further described below in the DetailedDescription. The Summary is not intended to identify key features oressential features of the claimed subject matter, nor is the Summaryintended as an aid in determining the scope of the claimed subjectmatter.

A method for applying a bioactive coating to an exterior surface of animplant within an operating room at a time of implantation is disclosed.In one embodiment, the method may include providing a mold of theimplant, providing, inserting, injecting, positioning, or the like (usedinterchangeably herein without the intent to limit) the bioactivecoating within the mold, and insetting the implant into the mold so thatthe exterior surface of the implant contacts the bioactive coating.Thereafter, the implant may be removed from the mold and the implantincluding any bioactive coating adhered thereto may be implanted into apatient.

In another embodiment, the method may include providing an implantwithin an interior cavity of a mold, injecting the bioactive coatinginto a space between the exterior surface of the implant and an interiorsurface defining the interior cavity, and removing the implant from themold.

In another embodiment, the method may include providing an annulus and,optionally, a delivery device, inserting the implant into an interiorcavity of the annulus, and injecting the bioactive coating onto theimplant via moving the annulus along a length of the implant.

In these and other embodiments, the implant may be a temporary spacerused in place of a permanent implant. For example, for patientssuffering from an infection, a previously implanted implant may need tobe replaced. In these situations, the temporary spacer may be coatedwith a bioactive coating within the operating room via any of themethods, devices, or systems described herein. The bioactive coating mayinclude an antibacterial material used to fight the infection.

Embodiments of the present disclosure provide numerous advantages. Forexample, they provide an easy to use and effective system and method forcoating an implant such as, for example, a temporary spacer, within anoperating room at the time of implantation. As such, any risksassociated with the shelf-life of the coating are alleviated.

Further features and advantages of at least some of the embodiments ofthe present invention, as well as the structure and operation of variousembodiments of the present invention, are described in detail below withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate exemplary approaches of thedisclosure, including the practical application of the principlesthereof, as follows:

FIG. 1 illustrates a side, cross-sectional view of an example of anembodiment for coating an implant using a mold in accordance with oneaspect of the present disclosure;

FIG. 2 illustrates a side, cross-sectional view of an example of analternate embodiment for coating an implant using a mold and a deliverydevice in accordance with one aspect of the present disclosure;

FIG. 3 illustrates a detailed, cross-sectional view of the exampleembodiment shown in FIG. 2;

FIGS. 4A-4D illustrate various steps of an example process for coatingan implant in accordance with one aspect of the present disclosure;

FIG. 5A illustrates a perspective view of an example of an embodimentfor coating an implant using an annulus and a delivery device inaccordance with one aspect of the present disclosure;

FIG. 5B illustrates a perspective view of the annulus shown in FIG. 5Acoating an implant;

FIG. 6A illustrates a perspective view of an example of an embodimentfor coating an implant using an annulus in accordance with one aspect ofthe present disclosure;

FIG. 6B illustrates a perspective view of the annulus shown in FIG. 6Acoating an implant;

FIG. 6C illustrates a perspective view of the annulus shown in FIG. 6Acoating an implant;

FIG. 7 illustrates a view of an example of an embodiment for coating animplant using a flexible container in accordance with one aspect of thepresent disclosure;

FIG. 8 illustrates a view of an example of an alternate embodiment forcoating an implant using a flexible container in accordance with oneaspect of the present disclosure;

FIGS. 9A and 9B illustrate various steps of an example process forcoating an implant in accordance with one aspect of the presentdisclosure; and

FIG. 10 illustrates a side, cross-sectional view of an example of anembodiment for coating an implant in accordance with one aspect of thepresent disclosure.

The drawings are not necessarily to scale. The drawings are merelyrepresentations, not intended to portray specific parameters of thedisclosure. The drawings are intended to depict example embodiments ofthe disclosure, and therefore are not be considered as limiting inscope. In the drawings, like numbering represents like elements.

Furthermore, certain elements in some of the figures may be omitted, orillustrated not-to-scale, for illustrative clarity. The cross-sectionalviews may be in the form of “slices”, or “near-sighted” cross-sectionalviews, omitting certain background lines otherwise visible in a “true”cross-sectional view, for illustrative clarity. Furthermore, forclarity, sonic reference numbers may be omitted in certain drawings.

DESCRIPTION

For the purposes of promoting an understanding of the principles of thepresent disclosure, reference will now be made to example embodiments.It will nevertheless be understood that no limitation of the scope ofthe disclosure is thereby intended. Any alterations and furthermodifications in the described embodiments, and any further applicationsof the principles of the present disclosure as described herein arecontemplated as would normally occur to one skilled in the art to whichthe disclosure relates.

The present disclosure is directed to devices, systems, and methods forallowing rapid and complete coverage of an implant with a bioactivecoating. In some embodiments, devices, systems, and methods are arrangedand configured to enable the bioactive coating to be applied within, forexample, the operating room just prior to implantation of the implant.In one embodiment, the method may include providing a mold, andinserting a bioactive coating within an interior cavity of the mold. Themethod may further include inserting the implant into the interiorcavity of the mold so that the exterior surface of the implant contactsthe bioactive coating. Thereafter, the implant, and the coating appliedthereto, may be removed from the mold.

As described herein, bioactive coatings may be any suitable coating nowknown or hereafter developed. For example, the bioactive coating may bea hydrogel or paste. Alternatively, and/or in addition, the bioactivecoating may be an antibacterial or antibiotic coating. Alternatively,and/or in addition, the bioactive coating may include bioceramics,extracellular matrix proteins, biological peptides or growth factorsimparting bioactivity and biocompatibility to the surface of the implantto promote bone ingrowth and differentiation of stem cells intoosteoblasts leading to enhanced osteointegration of the implant.Furthermore, the bioactive coatings may include silver, nitric oxide,antiseptics and antimicrobial peptides with anti-microbial properties,which reduce bacterial adhesion and prosthetic infections.

Referring to FIGS. 1-4D, in one example embodiment, a receptacle or mold100 (used interchangeably herein without the intent to limit) may beprovided and/or made. The mold 100 may be manufactured as a singlecomponent (as schematically illustrated in FIG. 1) or may bemanufactured from two or more components (as schematically illustratedin FIG. 2). In some embodiment, the mold 100 may include an interiorcavity 105 that has a shape corresponding to that of the implant 50 tobe coated, although such is not necessary. In some embodiments, the moldmay he, for example, part of the packaging materials used for theimplant 50, such as the tray that holds the implant 50 during, forexample, delivery.

In use, the interior surfaces 110 of the mold 100 may generally followthe shape and/or contours of an exterior surface 52 of the implant 50 tohe coated (as schematically illustrated in FIG. 2), although asschematically illustrated in FIG. 1, this is not necessary. in eitherevent, a gap 120 between the interior surfaces 110 of the mold 100 andthe exterior surfaces 52 of the implant 50 is created that may be filledwith a bioactive coating 175 so that, when the implant 50 is insertedinto the interior cavity 105 of the mold 100, the bioactive coating 175resides between the interior surfaces 110 of the mold 100 and theexterior surfaces 52 of the implant 50.

As used herein, the implant 50 may be any suitable implant now known orhereafter developed. For example, in some embodiments, the implant 50may be a femoral implant. In another embodiment, the implant 50 may be aknee implant, a hip implant, a spinal spacer, etc. In accordance withone particular aspect of the present disclosure, the implant 50 may be atemporary implant or spacer (used interchangeably herein without theintent to limit) made from, for example, bone cement (e.g., poly(methylmethacrylate)). The bioactive coating 175 may be, for example, anantibacterial coating used to fight infections. As will be appreciatedby one of ordinary skill in the art, a temporary spacer may be temporaryimplanted into the patient, for example, when a previously implantedimplant has been removed from a patient due to, for example, aninfection. The temporary spacer may be temporary implanted into thepatient while the patient fights the infection. Thereafter, thetemporary spacer may be removed from the patient and a new, permanentimplant may be implanted. Thus, for example, the spacer may be used, forexample, in the event of an infection due to a previously insertedimplant. After the existing implant and infected tissue are removed fromthe patient, the spacer is provided in its place. While implanted, theantibiotic coating may leach out of the spacer over a period of time.The spacer may then be removed and replaced with a permanent implantafter the patient has adequately healed. The spacer may be coated withthe bioactive coating 175 via any of the methods and devices describedherein.

The temporary spacer and the bioactive coating may he arranged andconfigured to promote better adhesion between the bioactive coating andthe spacer, and/or to provide better elution of the bioactive coatingduring use. For example, in one embodiment, the bioactive coating mayinclude one or more additives to enable better adhesion to the spacerthe additives may enable better adhesion to the spacer as compared to aconvenient implant). In addition, and/or alternatively, the spacer mayinclude one or more surface features such as, for example, stipples orthe like to assist with maintaining the antibiotic in place as thespacer is being implanted. In another embodiment, the spacer may be inthe formed from a bone cement such as, for example, PMMA, and maycontain an antibiotic material mixed therein. The spacer may furtherinclude one or more fissures or pockets formed on the surface of thespacer. These fissures or pockets could be loaded with an antibioticcoating and would provide an enhanced elution profile.

Referring to FIGS. 4A-4D, an example of a method for applying thebioactive coating 175 to the exterior surface 52 of the implant 50according to one aspect of the present disclosure will be described ingreater detail. Although non-limiting, the bioactive coating 175 may beapplied by a dip coating process. Examples of other suitable applicationmethods include, but are not limited to, spray coating, roll coating,electro coating, or combinations thereof.

As shown, at process (1) (FIG. 4A), the mold 100 is provided. The mold100 may define an interior cavity 105. At process (2) (FIG. 4B), theinterior cavity 105 of the mold 100 may be filled with the bioactivecoating 175 such as, for example, the hydrogel or paste. In someembodiments, the bioactive coating 175 may be an antibacterial solutionor material. In other embodiments, the bioactive coating 175 may be apowdered antibiotic. At process (3) (FIG. 4C), the implant 50 may beinserted into the interior cavity 105 of the mold 100. Once inserted,the bioactive coating 175 may be placed or positioned in direct contactwith the exterior surfaces 52 of the implant 50. In some embodiments,the implant 50 may include a plurality of fissures, indentations, orrecesses 58 formed in the exterior surface 52 of the implant 50 toprovide an enhanced elution profile. As shown at process (4) (FIG. 4D),the volume of bioactive coating 175 may be displaced to substantiallycoat the exterior surfaces 52 of the implant 50 within the interiorcavity 105 of the mold 100 to a. given thickness. The implant 50 is thenremoved along with the bioactive coating 175, which adheres to theexterior surfaces 52 of the implant 50,

In an alternate embodiment, as schematically illustrated in FIGS. 2 and3, the implant 50 may be inserted into the interior cavity 105 of themold 100 and then the bioactive coating 175 may be inserted or injectedinto the gap or space 120 between the exterior surface 52 of the implant50 and the interior surface 110 of the mold 100 via a delivery device150, such as, for example, a syringe. The bioactive coating 175 may beinjected through an injection port 130 formed in the mold 100. Theinjection port 130 is shown proximate a distal end 54 of the implant 50.However, the injection port 130, or multiple ports, may extend throughthe mold at different positions, Embodiments herein are not limited inthis context.

As further shown in FIG. 2, in some embodiments, the mold 100 mayinclude one or more surface features 112, such as ridges, projections,bumps, bearings, etc., on the interior surface 110 thereof to ensurethat the implant 50 is properly positioned within the interior cavity105 of the mold 100. The surface features 112 may ensure the gap 120 ispresent between the interior surfaces 110 of the mold 100 and theexterior surfaces 52 of the implant 50 so that, when the implant 50 isinserted into the mold 100, the bioactive coating 175 is evenly appliedto the exterior surfaces 52 of the implant 50.

Referring to FIGS, 5A-5B, in another example embodiment, an annulus 200may be used to coat the implant 50. For example, as shown, the annulus200 may include an interior cavity 205 for receiving a portion of theimplant 50 therein and one or more apertures 210, such as holes or slotson the surface thereof. For example, the apertures 210 may be positionedadjacent to, or in close proximity to, the interior cavity 205. In use,the annulus 200 may be connected to a delivery device 250 such as, forexample, a syringe, containing the bioactive coating 175 so that thebioactive coating 175 may be injected into the annulus 200, through heapertures 210 formed in the annulus 200, and onto the implant 50positioned within the interior cavity 205. The annulus 200 may bemanufactured from any suitable material and/or manner now known orhereafter developed. For example, the annulus 200 may be flexible orrigid.

In use, an implant 50 such as, for example, a hip stem, may bepositioned within the interior cavity 205 of the annulus 200. Next, asschematically illustrated in FIG. 5B, the annulus 200 may be moved alongthe length of the implant 50 while simultaneously injecting thebioactive coating 175 onto the implant 50. In other embodiments, asshown in FIGS. 6A-6C, the annulus 200 may be pre-filled with an adequateamount of bioactive coating 175 to render simultaneous injection via thedelivery device 250 unnecessary. In use, the annulus 200 may be moved orslid along the length of the implant 50. Pressure applied by an operatoras the annulus 200 is moving along the implant 50 may cause thebioactive coating 175 to secrete from the apertures 210.

Referring to FIG. 7, in another example embodiment, a flexible container300, such as a bag, may be used in place of the mold. In use, thebioactive coating 175 may be placed inside of the flexible container300. Next, the implant 50 may be placed in the flexible container 300and the bioactive coating 175 may be manipulated to coat the surfaces ofthe implant 50.

Alternatively, referring to FIG. 8, an alternate example of anembodiment of a flexible container 400 may include a nozzle 410. In use,a bioactive coating 175 may be placed inside of the flexible container400. The nozzle 410 may then be used to spread or coat the bioactivecoating 175 over the exterior surfaces 52 of the implant 50. In someembodiments, the flexible container 400 may include more than one nozzle410.

Referring to FIGS. 7 and 8, in an alternate embodiment, the bioactivecoating 175 may be provided, for example, in a two-part solution andsubsequently mixed within the flexible container 300, 400. For example,the bioactive coating 175 could be provided as a two-part mixture baggedtogether within the flexible container 300, 400 but separated by, forexample, a breakable seam. In use, the seam could be broken bringingtogether the two solutions to form the bioactive coating 175.Alternatively, one solution may be located within the flexible container300, 400 while the other may be injected inside of the flexiblecontainer 300, 400 just prior to or during use. In any event, theflexible container 300, 400 may then be manipulated to mix the solutionstogether. Finally, the flexible container 300, 400 may be used as adelivery mechanism to coat the implant 50.

Referring to FIGS. 9A and 9B, in another embodiment, a bioactive coating175 can be applied to the surfaces of the implant 50 in the operatingroom by, for example, wetting the surfaces of the implant 50. In use,the implant 50 may be wetted by any mechanism now known or hereafterdeveloped, for example, in one embodiment, the implant 50 may be wettedusing a water spray. Alternatively, as illustrated at process (1) (FIG.9A), the implant 50 may be inserted into a first container 500containing water 502 therein. Next, at process (2) (FIG. 9B), theimplant 50 may be inserted into a second container 510 containing, forexample, a powder 512 including the bioactive component such as, forexample, a bioactive and de-hydrated gel. As a result, the powder 512containing the bioactive and de-hydrated gel may adhere to the dampsurfaces of the implant 50. Alternatively, the powder 512 could besprinkled onto the damp surfaces of the implant 50. Next, the implant 50and powder 512 may be inserted into saline or water to form the finalgel coating.

Referring to FIG. 10, in another embodiment, the implant 50 may bepre-coated with, for example, a de-hydrated hydrogel, which may be inthe form of an adhesive, such as a tape 610. The implant 50 and the tape610 may be immersed in a hydrating solution 602 (e.g., water or saline)positioned within an interior cavity of a receptacle or mold 600 to forma bioactive coating 175 such as, for example, a hydrogel, on the surfaceof the implant 50. In the embodiment shown, the tape 610 may be wrappedand/or applied to the implant 50 in, for example, the operating room.Once the tape 610 is applied to the implant 50, the implant 50 and thetape 610 may be placed in the interior cavity of the receptacle or mold600 containing the hydrating solution 602 to form the bioactive coating175 on the surface of the implant 50. In other embodiments, thehydrating solution 602 may be applied to the tape 610 in other ways,such as by spraying.

Although non-limiting, the tape 610 may be a biocompatible material,such as woven, non-woven, knitted, braided or crocheted, foam, sponge,or dendritic material. The tape 610 may also be a polymeric film ormembrane or a mixture of two or more of these materials. Furthermore,the tape 610 may be porous or non-porous.

In one example embodiment, the bioactive coating (e.g., gel or paste)could be placed within a degradable, flexible container, such asflexible containers 300, 400 described above. The flexible container maybe made from, for example, a rapidly degrading or soluble material whichcan be implanted into the patient together with the implant. Theflexible container may degrade or dissolve once implanted. For example,the flexible container could degrade within approximately 2-3 hours ofimplantation. Embodiments are not limited in this context, however.

As used herein, bioactive coatings, such as bioactive coatings 175 mayinclude a titanium substrate having silver deposited thereon, whereinthe silver is operable to be eluted at an intended rate. As described inPCT Application No. PCT/US2017/014894, entitled Orthopaedic Implant, theentire content of which is hereby incorporated by reference, the silverdeposited on the titanium substrate suitably includes silver ions and/orsilver nanoparticles. The silver ions and/or silver nanoparticles may bedispersed either within or on top of a titanate nanostructure. In someembodiments, the bioactive coating may be a polymeric coating. Forexample, the implant may alternatively include a titanium substratehaving silver deposited thereon, and further coated with a polymericcoating. Advantageously, adding a polymeric coating enables a controlledrelease of the silver from the implant into the body. This allows for abeneficial sustained controlled release of the silver and also reducesthe cytotoxicity of large amounts of silver being released into thebody. In some embodiments, the polymeric coating is

Non-limiting examples of suitable natural polymers include, but are notlimited to, one or more of the following: hemaleucin; gelatin; starch;cellulose; chitosan; collagen; or combinations thereof. Suitably, thepolymeric material may comprise hemaleucin, gelatin or a combinationthereof. Non-limiting examples of suitable synthetic polymers include,but are not limited to, one or more of the following: polyesters suchas, for example, polylactides (including poly-D-lactides,poly-L-lactides, poly˜D,L-lactides and combinations thereof), polyglycosides, polylactide-polyglycolide copolymers includingpoly-D-lactide-polyglycolide copolymers, poly-L-lactide-polyglycolidecopolymers, poly-D,L-lactide-polyglycolide copolymers and combinationsthereof) and polyester-polyethylene glycol (PEG) copolymers;polyorthoesters; polyamino acids; polyurethanes; or combinationsthereof. Suitably, the polymeric material may comprise poly-D,Lactide-polyglycolide copolymers, poly-D,L-lactides or a combinationthereof.

As used herein, examples of hydrogels which may be used according toembodiments of the present disclosure may be collagen (particularly Type1), fibrin, TETRONICS™ and POLOXAMINES™, which arepoly(oxyethylene)-poly(oxypropylene) block copolymers of ethylenediamine; polysaccharides, chitosan, polyvinyl amines), poly(vinylpyridine), poly(vinyl imidazole), polyethylenimine, poly-L-lysine,growth factor binding or cell adhesion molecule binding derivatives,derivatised versions of the above, e.g. polyanions, polycations,peptides, polysaccharides, lipids, nucleic acids or blends,block-copolymers or combinations of the above or copolymers of thecorresponding monomers; agarose, methylcellulose,hydroxyproylmethylcellulose, xyloglucan, acetan, carrageenan, xanthangum/locust beangum, gelatine, collagen (particularly Type 1),PLURONICS™, POLOXAMERS™, POLY(N-isopropylacrylmide) andN-isopropylacrylmide copolymers.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralelements or steps, unless such exclusion is explicitly recited.Furthermore, references to “one embodiment” of the present disclosureare not intended to be interpreted as excluding the existence ofadditional embodiments that also incorporate the recited features.

The use of “including,” “comprising,” or “having” and variations thereofherein is meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Accordingly, the terms “including,”“comprising,” or “having” and variations thereof are open-endedexpressions and can be used interchangeably herein.

All directional references (e.g., proximal, distal, upper, lower,upward, downward, left, right, lateral, longitudinal, front, back, top,bottom, above, below, vertical, horizontal, radial, axial, clockwise,and counterclockwise) are only used for identification purposes to aidthe reader's understanding of the present disclosure, and do not createlimitations, particularly as to the position, orientation, or use ofthis disclosure. Connection references (e.g., attached, coupled,connected, and joined) are to be construed broadly and may includeintermediate members between a collection of elements and relativemovement between elements unless otherwise indicated. As such,connection references do not necessarily infer that two elements aredirectly connected and in fixed relation to each other.

Furthermore, identification references e.g., primary, secondary, first,second, third, fourth, etc.) are not intended to connote importance orpriority, but are used to distinguish one feature from another. Thedrawings are for purposes of illustration only and the dimensions,positions, order and relative sizes reflected in the drawings attachedhereto may vary.

Furthermore, the terms “substantial” or “substantially,” as well as theterms “approximate” or “approximately,” can be used interchangeably insome embodiments, and can be described using any relative measuresacceptable by one of ordinary skill in the art. For example, these termscan serve as a comparison to a reference parameter, to indicate adeviation capable of providing the intended function. Althoughnon-limiting, the deviation from the reference parameter can be, forexample, in an amount of less than 1%, less than 3%, less than 5%, lessthan 10%, less than 15%, less than 20%, and so on.

Still furthermore, although the illustrative methods are described aboveas a series of acts or events, the present disclosure is not limited bythe illustrated ordering of such acts or events unless specificallystated. For example, some acts may occur in different orders and/orconcurrently with other acts or events apart from those illustratedand/or described herein, in accordance with the disclosure. in addition,not all illustrated acts or events may be required to implement amethodology in accordance with the present disclosure. Furthermore, themethods may be implemented in association with the formation and/orprocessing of structures illustrated and described herein as well as inassociation with other structures not illustrated.

The present disclosure is not to be limited in scope by the specificembodiments described herein. Indeed, other various embodiments of andmodifications to the present disclosure, in addition to those describedherein, will be apparent to those of ordinary skill in the art from theforegoing description and accompanying drawings. Thus, such otherembodiments and modifications are intended to fall within the scope ofthe present disclosure. Furthermore, the present disclosure has beendescribed herein in the context of a particular implementation in aparticular environment for a particular purpose. Those of ordinary skillin the art will recognize the usefulness is not limited thereto and thepresent disclosure may be beneficially implemented in any number ofenvironments for any number of purposes. Thus, the claims set forthbelow are to be construed in view of the full breadth and spirit of thepresent disclosure as described herein.

What is claimed is:
 1. A method for applying a bioactive coating to anexterior surface of an implant within an operating room at a time ofimplantation, the method comprising: providing a mold having an interiorcavity; positioning the bioactive coating within the interior cavity ofthe mold; inserting the implant into the interior cavity of the mold sothat the exterior surface of the implant contacts the bioactive coating;and removing the implant from the interior cavity of the mold along withthe bioactive coating adhered thereto.
 2. The method of claim 1, furthercomprising forming a plurality of recesses in the exterior surface ofthe implant prior to inserting the implant into the mold.
 3. The methodof claim 1, wherein the implant is a temporary spacer.
 4. The method ofclaim 3, wherein the spacer is formed from a bone cement and thebioactive coating is an antibiotic coating for fighting an infection. 5.The method of claim 1, wherein positioning the bioactive coating withinthe mold comprises depositing an antibiotic coating within the interiorcavity of the mold.
 6. The method of claim 5, further comprisingproviding one or more surface features on an internal surface of theinterior cavity of the mold to enable positioning of the implant withinthe interior cavity of the mold.
 7. The method of claim 1, furthercomprising: wetting the exterior surface of the implant; inserting theimplant into a powder including bioactive coating; and inserting theimplant and powder into saline or water to form a gel coating.
 8. Themethod of claim 1, wherein the mold is part of packaging materials usedfor delivering the implant.
 9. A method for applying a bioactive coatingto an exterior surface of an implant within an operating room at a timeof implantation, the method comprising: inserting the implant within aninterior cavity of a mold; injecting the bioactive coating into a spacebetween the exterior surface of the implant and an interior surfacedefining the interior cavity of the mold; and removing the implant andthe bioactive coating adhered thereto from the interior cavity of themold.
 10. The method of claim 9, wherein the implant is a temporaryspacer formed from a bone cement and the bioactive coating is anantibiotic coating for fighting an infection.
 11. The method of claim 9,wherein injecting the bioactive coating within the interior cavity ofthe mold comprises injecting an antibiotic coating within the interiorcavity of the mold.
 12. The method of claim 9, further comprisingproviding one or more surface features on an internal surface of theinterior cavity of the mold to enable positioning of the implant withinthe interior cavity of the mold.
 13. The method of claim 9, furthercomprising coating the implant with a liquid prior to inserting theimplant into the interior cavity of the mold, wherein the bioactivecoating is a powdered antibiotic, and wherein the liquid causes thepowdered antibiotic to adhere to the exterior surface of the implant.14. The method of claim 9, further comprising: coating the implant witha de-hydrated hydrogel; and immersing the implant in a hydratingsolution containing the bioactive coating to form a bioactive containinghydrogel on the exterior surface of the implant.
 15. The method of claim14, wherein coating the implant with a de-hydrated hydrogel compriseswrapping the implant in a tape comprising the de-hydrated hydrogel. 16.A method for implanting a temporary spacer into a patient suffering froman infection, the method comprising: removing a previously insertedimplant from a patient; providing a temporary spacer; coating thetemporary spacer in an operating room with a bioactive coating; andimplanting the temporary spacer into the patient.
 17. The method ofclaim 16, wherein the spacer is formed from a bone cement and thebioactive coating is an antibiotic coating for fighting an infection.18. The method of claim 17, wherein the antibiotic coating leaches outof the spacer over a period of time.
 19. The method of claim 16, whereinthe temporary spacer and the bioactive coating are arranged andconfigured to promote better adhesion between the bioactive coating andthe spacer and to provide better elution of the bioactive coating. 20.The method of claim 16, wherein the temporary spacer includes one ormore pockets formed therein, the pockets containing an antibioticcoating.